Maintenance access zones for storage and retrieval systems

• US 10,005,624 B2
• Filed: 03/21/2017
• Issued: 06/26/2018
• Est. Priority Date: 12/15/2010
• Status: Active Grant

• Current Assignee: Symbotic, Llc
• Original Assignee: Symbotic, Llc
• Inventors: Cyrulik, Michael, Sullivan, Robert
• Primary Examiner(s): Cumbess, Yolanda R
• Application Number:
  US15/465,347
• Publication Number:
  US 20170190516A1
• Time in Patent Office: 462 Days
• Field of Search: None
• CPC Class Codes: B65G 1/0492 with cars adapted to travel in storage aisles
• CPC Class Codes: B65G 1/06 with means for presenting articles for removal at predetermined position or level B65G1/12 takes precedence
• CPC Class Codes: B65G 1/1373 for fulfilling orders in warehouses
• CPC Class Codes: B65G 2207/40 Safety features of loads, equipment or persons
• CPC Class Codes: B65G 47/883 Fixed stop

Abstract

A maintenance access system for a storage and retrieval system having a storage and retrieval space and automated transport vehicles disposed in the space. The system includes at least one maintenance access control unit associated with a portion of the space, at least one barrier in the space and defining a boundary of the portion of the space and configured to substantially prevent the passage of the vehicles past the at least one barrier, and a controller connected to the control unit, the controller being configured to receive a signal from the at least one control unit for isolating the portion of the space associated with the at least one control unit, where the controller in response to the signal closes the at least one barrier isolating the portion of the space and effects the removal from or shutting down of vehicles within the portion of the space.

Claims

1. A method of operating an automated warehouse system comprising:

providing a multilevel storage structure including a plurality of storage locations arranged on sides of picking aisles disposed in rows on each level so that the picking aisles of a respective row are stacked one above the other, each level having more than one shelf level on which the plurality of storage locations are disposed;

providing at least one autonomous transport vehicle that travels along the stacked picking aisles for transferring items to and from the storage locations of the more than one shelf level;

disposing maintenance access zones within and coincident with the stacked picking aisles and defining the maintenance access zones at least in part by the sides with the storage locations of the more than one shelf level of the stacked picking aisles in at least one row, so that each maintenance access zone provides continuous access to multiple levels of the stacked picking aisles that are in communication with each other and the more than one shelf levels on the sides corresponding to each of the multiple levels of picking aisles; and

supporting the at least autonomous transport vehicle for travel through a respective picking aisle with at least one rail included within the picking aisles, where the at least one rail is common to the more than one shelf level of at least one level of the stacked picking aisles and the at least one rail is configured so as to provide access to the more than one shelf level of the at least one level of the stacked picking aisles.

2. The method of claim 1, further comprising providing the at least one autonomous transport vehicle with a transfer arm configured to transfer items to and from the storage locations of the more than one shelf level.

3. The method of claim 1, further comprising transferring case units to and from the storage locations of the more than one shelf level with the at least one autonomous transport vehicle.

4. The method of claim 1, wherein the rows form a horizontal array of picking aisles that form a horizontal array of maintenance access zones.

5. The method of claim 1, further comprising providing the at least one autonomous transport vehicle access to at least one of one or more picking aisles and one or more vertical lift transfer areas with a transfer deck.

6. The method of claim 1, further comprising transferring items between a vertical lift and the storage locations of the more than one shelf level with the at least one autonomous transport vehicle at a vertical lift transfer area.

7. The method of claim 1, wherein the multiple levels of the stacked picking aisles are arranged in a vertical stack and a picking aisle at a bottom of the vertical stack includes a floor and picking aisles above the picking aisle at the bottom of the vertical stack for a respective maintenance access zone are substantially floorless.

9. The automated warehouse system of claim 2, wherein the at least one autonomous transport vehicle includes a transfer arm configured to transfer items to and from the storage locations of the more than one shelf level.

10. The automated warehouse system of claim 2, wherein the at least one autonomous transport vehicle is configured to transfer case units to and from the storage locations of the more than one shelf levels.

11. The automated warehouse system of claim 2, wherein the rows form a horizontal array of picking aisles that form a horizontal array of maintenance access zones.

12. The automated warehouse system of claim 2, wherein the at least one autonomous transport vehicle access to at least one of one or more picking aisles and one or more vertical lift transfer areas with a transfer deck.

13. The automated warehouse system of claim 2, further comprising a vertical lift transfer area that allows the at least one autonomous transport vehicle to transfer items between the storage locations of the more than one shelf level and a vertical lift.

14. The automated warehouse system of claim 2, wherein the multiple levels of the stacked picking aisles are arranged in a vertical stack and a picking aisle at a bottom of the vertical stack includes a floor and picking aisles above the picking aisle at the bottom of the vertical stack for a respective maintenance access zone are substantially floorless.

8. An automated warehouse system comprising:

a multilevel storage structure including a plurality of storage locations arranged on sides of picking aisles disposed in rows on each level of the multilevel storage structure so that the picking aisles of a respective row are stacked one above the other, each level having more than one shelf levels on which the plurality of storage locations are disposed;

at least one autonomous transport vehicle configured to travel along the stacked picking aisles for transferring items to and from the more than one shelf levels;

maintenance access zones disposed within and coincident with the stacked picking aisles and defined at least in part by the sides with the storage locations of the more than one shelf level of the stacked picking aisles in at least one row, so that each maintenance access zone provides continuous access to multiple levels of the stacked picking aisles that are in communication with each other and the more than one shelf levels on sides corresponding to each of the multiple levels of picking aisles; and

at least one rail, disposed within the picking aisles, configured to support the at least one autonomous transport vehicle for travel through a respective picking aisle, where the at least one rail is common to the more than one shelf level of at least one level of the stacked picking aisles and the at least one rail is configured to provide access to the more than one shelf levels of the at least one level of the stacked picking aisles.